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Accidents in chemical production usually result in fatal injuries, economic losses, and negative social impacts. To ensure personnel security in such cases, previous research has often used digital data, such as physical signals. However, the valuable textual information contained in chemical security texts, such as expert knowledge, has not yet been explored. Therefore, there is an increasing demand to mine useful information from these unstructured data. In this study, natural language processing (NLP) was applied to the hazard and operability (HAZOP) analysis reports. The classification model was trained to learn the classification of consequence severity levels in high-quality HAZOP analysis reports, which will not only ensure the consistency of the analysis results, but also help smaller chemical plants perform security analysis. In the classification model, we introduced Bidirectional Encoder Representation from Transformers (BERT), which, for word embedding, which is a powerful NLP pre-training model and significantly improved the effectiveness of the model. Through these application scenarios, the feasibility and possibility of applying NLP in chemical security text have been confirmed to a certain extent. In addition to digital data, future security managers will be able to monitor chemical production using natural language.

Background: In the production process, small accidents often occur between fellow workers in the production area, such as workers colliding with each other during the transfer process from one process to the next which causes the product to spill and workers fall, causing injury. PT. XYZ is a company engaged in the seafood industry, especially canning crabs. The company's production process applies a Good Manufacturing Practice (GMP) system with 12 work areas and 80% of the process is still done manually. Purpose: The purpose of this study is to identify risks and control the implementation of the HACCP system in the crab canning industry using the HAZOP method. Method: This type of research is a descriptive study, using the HAZOP (Hazard and Operability) method. The research was carried out at 12 nodes, namely receiving, checking aroma, sorting, mixing and filling, metal detecting, weighing, seaming, pasteurization, chilling, packing, and sanitation. Result: The results showed 4 risk ratings, namely low, medium, high, and extreme risk based on 8 sources of potential hazards. The biggest risk that is extreme is in node seaming. Conclusion: Based on processing data, 8 sources of potential hazards that can occur in the pasteurized crab meat production room. The recommendations given are to implement elimination, reduction, engineering control, administrative control, Personal Protective Equipment, work attitude improvement, and OHS training.

There are many techniques for hazard identification and are divided into shortcut, standard and advanced techniques. Among these, HAZOP and What-If techniques are mostly engaged by practitioners in the chemical process industry. Both of these have certain advantages and limitations, i.e., HAZOP is structured, and what-if covers broad range of scenarios. There is no hazard identification method, which can cover a broad range of scenarios and is structured in nature. For this purpose, a new technique namely integrated hazard identification (IHI) is proposed in this article that integrates HAZOP and What-If. The methodology is demonstrated via hazard identification study of urea synthesis section. Risk ranking is used to sort out the worst-case scenario. This worst-case scenario is further studied in detail for quantification that is performed using the ALOHA software. This quantification has assisted to detect ammonia concentrations in nearby control room and surroundings for worst-case scenario. It is revealed that if ammonia pump is not stopped within 10 minutes, concentration inside and outside the control room may reach to 384 ppm and 2630 ppm, compared to 1100 ppm (AEGL-3). Thus the proposed method would be easy, time saving and covers more details and would be handy for practicing engineers working in different chemical process industries.

Occupational Safety and Health (OSH) is an important aspect to pay attention to in the workplace. This is due to the workplace environment that has potential hazards and risks that can cause work-related accidents and diseases. Accidents and occupational diseases need to be prevented and minimized because they reduce work productivity and harm workers and business owners. The risk of accidents and occupational diseases also exists in the informal batik sector. One of the informal Batik sectors in Banyumas Regency is Batik Papringan. Papringan Batik workers have not implemented the OSH Standard Operational Procedure (SOP). This causes workers to experience health complaints such as coughing, itching, and musculoskeletal conditions. Therefore, it is necessary to analyze occupational accidents and diseases with the Hazard and Operability Study (HAZOP) and its control. The research objective was to determine the hazards and risks of accidents and diseases due to the work of Batik Papringan workers. The method used is the HAZOP method. The results showed that the stooped and static sitting posture, exposure to chemicals from wax smoke and dyes and the absence of 5R (Ringkas, Rapi, Resik, Rawat, Rajin) were hazards that pose extreme risks. Risk control in the form of ergonomic work place and equipment design and compliance with the 5R and the use of PPE are the most prioritized risk controls. The conclusion from this research is that the implementation of risk control in the form of ergonomic work place and equipment design, fulfilling the 5R and the use of PPE need to be done continuously to prevent accidents and occupational diseases. Keywords: Accident, diseases, HAZOP, control, batik

Work accidents are things that must be avoided, so that's not inflicted loss on the company and the workers. However, several workers still not pay attention to occupational health and safety regulations and in the work area still found several potential hazards. The research is conducted at PT Pindo Deli Pulp and Paper Mills Indonesia in Karawang Regency and focuses on preventive and corrective maintenance activities that prevent paper machine breakdown. The purpose of this study is to measure how big the potential hazard and impact by using Hazard and Operability Study (HAZOP) method. This method is a systematic study, which aims to find the factors that causing work accidents and find out how big the potential accidents and their impacts. The data is collected by distributing questionnaires to the employee. The results show that hazards caused by the work area and the workers themselves are 18% and 82%, respectively. Based on the severity, the number of extreme, high, medium and low risk hazards are 1, 8, 1 and 1, respectively.

Many researchers report optimizations of chemical processes based on steady-state analysis. However, neglecting the time factor may lead sometimes to more waste generation and/or hazardous safety consequences. In this regard, we recently detailed a comprehensive modeling of a fluidized bed reactor (FBR) for Unipol® polypropylene process using the sequential modular simulation approach while incorporating the hydrodynamic correlations. Furthermore, a steady-state analysis and optimization technique was used to increase the plant profitability. The current manuscript presents dynamic modeling to identify process constraints that obstruct the process improvement recommended by the previous study. The current dynamic model was validated using industrial operational scenarios. The dynamic model was then utilized to explore the response of the FBR control system protection layer to unplanned operational scenarios, its ability to avoid waste generation, and achieve process safety. As such, an automated HAZOP study based on layer of protection analysis concept was applied for this purpose. As a result, to apply the recommended scheme by the steady-state study while ensuring safety and cleaner production in the process, it is necessary to revamp the existing FBR cooling system. The extra cost for revamping the cycle gas cooler is trivial compared to the potential increase in the process safety besides the plant productivity.

Recently, a new industrial relevant wastewater (water/Cyclohexane/sec-butyl alcohol) separation process with vapor recompression and thermal coupling was proposed as the conventional homogeneous extractive distillation. This highly integrated and interactive multivariable process presents great challenges to the dynamic controllability and process safety analysis. In this paper, based on the concept of “simultaneous design”, the newly proposed process is systematically investigated from the perspective of process improvement, plantwide control and safety analysis. Firstly, for energy conservation and CO2 emission reduction, the new complex process is further improved by applying the features of heterogeneous distillation. And a modified heterogeneous distillation process with heat pump is proposed, which can save reboiler duty about 16.8 % and save compressor electricity up to 67.7 %, while the reduction of CO2 emissions is 23.5 %. Secondly, for the efficient heterogeneous distillation process, an effective and robust plantwide control strategy is developed and tested under large throughput and feed composition disturbances. Last, with the dynamic simulation assisted HAZOP, a quantitative safety analysis is conducted, which can help experts to consider the nature, scale and response time of hazards and identify the potential propagation of deviation between different units, and then propose more specific or accurate safety recommendations correspondingly.

The availability of repair garage infrastructure for hydrogen fuel cell vehicles is becoming increasingly important for future industry growth. Ventilation requirements for hydrogen fuel cell vehicles can affect both retrofitted and purpose-built repair garages and the costs associated with these requirements can be significant. A hazard and operability (HAZOP) study was performed to identify risk-significant scenarios related to light-duty hydrogen vehicles in a repair garage. Detailed simulations and modeling were performed using appropriate computational tools to estimate the location, behavior, and severity of hydrogen release based on key HAZOP scenarios. This work compares current fire code requirements to an alternate ventilation strategy to further reduce potential hazardous conditions. Modeling shows that position, direction, and velocity of ventilation have a significant impact on the amount of instantaneous flammable mass in the domain.

In this study, a comprehensive approach based on the Fuzzy Bayesian Network (FBN) was presented to reduce completeness, modeling, and parameter uncertainties and to analyze the risk of hazardous material release in floating roof storage tanks accurately. In this method, managerial, organizational, human and process factors, were investigated using human and process HAZOP technique before the occurrence of accident scenarios. These factors were examined after the intended scenario in a sequential modeling approach based on SHIPP methodology as a barrier model. Moreover, according to the initial probabilities and interference of barriers, the relevant conditional probability tables (CPTs) were modified by utilizing l -NOR gates, and the accident scenario model was developed using the Bow-tie (BT) model. Triangular fuzzy numbers and expert opinion incorporated into the Bayesian network to deal with the uncertainty in the occurrence probability of basic events and safety barriers. The methanol storage tank was selected to present the applicability potential of the proposed model. The results showed that the validation of the position and conditional probabilities (CPs) of barriers in the BT structure will reduce the uncertainties, and the combination of FBN and l NOR gate is an appropriate way to evaluate the risk of tanks accurately.

In this work, we have focused on the risks emanating from the steam production process in a thermal production department with a view to reducing the occurrence of unwanted events. The practical aspect of this study is to ensure the well-being of production actors and the surrounding population. Subsequently, we opted for fault tree analysis and HAZOP, which are tools for studying the probabilities of occurrence of unwanted events in the operation of industrial thermal installations. In addition, in the process of steam production, it emerges that pressure and temperature remain the most important parameters to monitor in order to reduce the risks associated with chemicals but especially with steam circuits.

Multi-criteria Decision Making (MCDM) is widely used for problem-solving in various research fields and has shown good results in risk analysis as well. However, given the gaps found in previous studies in the context of risk analysis, this article proposes and conducts a novel MCDM-based HAZOP analysis: a hybrid methodology with an MCDM approach, Strategic Options Development and Analysis (SODA), and Intuitionistic Fuzzy Sets (IFS). We combine their advantages by using SODA with Intuitionistic Fuzzy Cognitive Maps and by reducing the inherent uncertainty and subjectivity of HAZOP with an IFS-based MCDM sorting algorithm. To demonstrate the usefulness and flexibility of this approach, a real application with a continuous pyrolysis system was conducted, and a comparative analysis was made of the main related studies to demonstrate the advantages of the approach now proposed. On applying it, 40 hazards were identified (seven more than a previous analysis conducted in 2016), and only 3 (7.5 %) of them required special attention. Among the positive points highlighted by the team, the most cited were the resource-saving, greater focus and objectivity, and a more realistic perception of hazards. In particular, we show that our methodology is more consistent and appropriate than those in previous related articles. To assist future users, we provide a framework for the application.

Many continuous industrial processes operate in different steady states with different grades or products. The switching between two steady states is called transition. Transition consists of a series of operation changes that should be carried out in proper order, within certain magnitudes and time region. Since faulty operation may lead to increase in inferior products or even hazard events, monitoring of the transition is desired. In this work, a transition identification and monitoring scheme is proposed based on slow feature analysis. Two monitoring statistics which represent the location of the trajectory and the speed of transition are proposed. Besides, operating faults are generated based on the guidewords of hazard and operability analysis (HAZOP). Using a numerical case and the mode 4-to-2 transition of the Tennessee-Eastman process in which catastrophic failures exist, the effectiveness of the proposed method is validated. In addition to missed detection rate and false alarm rate, two performance indexes known as detection time (DT) and rescue time (RT) are introduced. The advantages of proposed method are benchmarked against the stage-based sub principle component analysis(sub-PCA) and the global preserving statistics slow feature analysis(GSSFA).

PurposeThe increasing complexity of industrial systems is at the heart of the development of many fault diagnosis methods. The artificial neural networks (ANNs), which are part of these methods, are widely used in fault diagnosis due to their flexibility and diversification which makes them one of the most appropriate fault diagnosis methods. The purpose of this paper is to detect and locate in real time any parameter deviations that can affect the operation of the blowout preventer (BOP) system using ANNs.Design/methodology/approachThe starting data are extracted from the tables of the HAZOP (HAZard and OPerability) method where the deviations of the parameters of normal BOP operating (pressure, flow, level and temperature) are associated with an initial rule base for establishing cause and effect of relationships between the causes of deviations and their consequences; these data are used as a database for the neural network. Three ANNs were used, the multi-layer perceptron network (MLPN), radial basis functions network (RBFN) and generalized regression neural networks (GRNN). These models were trained and tested, then, their comparative performances were presented. The respective performances of these models are highlighted following their application to the BOP system.FindingsThe performances of the models are evaluated using determination coefficient (R2), root mean square error (RMSE) and mean absolute error (MAE) statistics and time execution. The results of this study show that the RMSE, MAE and R2 values of the GRNN model are better than those corresponding to the RBFN and MLPN models. The GRNN model can be applied with better performance, to establish a diagnostic model that can detect and to identify the different causes of deviations in the parameters of the BOP system.Originality/valueThe performance of the trained network is found to be satisfactory for the real-time fault diagnosis. Therefore, future studies on modeling the BOP system with soft computing techniques can be concentrated on the ANNs. Consequently, with the use of these techniques, the performance of the BOP system can be ensured performing only a limited number of monitoring operations, thus saving engineering effort, time and funds.

Global demand for liquefied natural gas (LNG) is projected to double by 2040, with gas playing a significant role in a less carbon-intensive power system, to 700 million tons. The risk assessment and vulnerability analysis of liquefied natural gas regasification plant have predominant importance due to increase in demand. Determination of safety integrity level (SIL) for process industries becomes a contemporary relevant factor. The reliability of various equipment used in process plants is critically important to maintain safety standards; malfunctions of these instruments may result in accidents which will affect property, environment and people. The main aim of the work is the risk assessment of liquefied natural gas to identify and rank failures that could result in the release of liquefied natural gas to the surrounding environment. In this paper, we integrate fuzzy risk matrix and layer of protection analysis (LOPA) to find safety integrity level value of each Independent Protection Layer (IPL) of seven scenarios of the liquefied natural gas storage facility. Seven scenarios were identified using hazard and operability analysis (HAZOP) as a process hazard analysis (PHA) tool, and we compare the safety integrity level value with Field Device Tool (FDT) method and risk graph is used to find the risk reduction factor (RRF). The safety integrity level determination using fuzzy methods gives more accurate result when compared with the risk graph methods and also describes the safety issues and hazard characteristics in liquefied natural gas terminal and consequence analysis if a liquefied natural gas tanker at the terminal releases liquefied natural gas due to natural and external man-made events, like recent issues between Saudi and Iran regarding oil transporting through Arabian Gulf, and accidents due to projectile effects. Process Hazard Analysis Software Tool (PHAST) and ALOHA software enable to analyse consequence having exorbitant complexity all while considering weather conditions, usage of land and population in the locality. In this paper, atmospheric dispersion modelling and evaluation of flammable and toxic effects have been done by Process Hazard Analysis Software Tool 8.11. Relationship between SIL, PFDavg and RRF is analysed. The frequency, severity and risk values are also gathered. Fuzzy risk values and SIL for each IPL from fuzzy LOPA are obtained, and furthermore, risk reduction SIL values, FDT method to calculate SIL and release scenario are investigated. Comparing the SIL values from fuzzy LOPA approach and FDT method, the consequence analysis of LNG spills from carrier ship due to natural cause using PHAST 8.11 and LNG leak from carrier ship due to man-made cause using ALOHA is also investigated.

Hazard and operability (HAZOP) analysis has a well-deserved reputation for systematic and thorough evaluation of process hazards in industrial units. The method is now widely known and is in prevalent use in the chemical processing industries; so much so that in many industries performing a HAZOP has become a legal requirement for new or modified industrial units. A number of guides exist for conducting HAZOPs, the most recent being the IChemE guidelines on finest practice – second edition, published in the year 2008. In exercise however, following best practice is not that easy and many compromises have to be made in order to finish the task an added hurdle occurs when the HAZOP is led by a self-governing leader from an external company or third party as is increasingly the case. In this circumstance the person in charge also has to satisfy the customer or customer’s requirements which do not always match to the best custom. In addition there is a drift to lessen HAZOP study scope to safety health and environmental concerns only and to exclude operability and consistency issues. This has resulted from a observance mindset, possibly in an attempt to lessen liabilities. HAZOP is increasingly being seen as a conformity tool rather than as a tactic to ensure a secure, trustworthy and well designed plant. With the current financial environment we can expect these hitches to increase as project costs come under enhanced pressure and the extent of many projects is reduced. This paper discusses some of the more frequent crisis that occur during HAZOPs and some of the possible solutions in industrial units.

A potential hazard can happen because of a technical and personal failures, natural disasters, terrorist attacks, and fires. The potential hazards can be dangerous for human health and environment, also cause economic losses. In an industrial plant, prevention and control of these consequences have an importancy. Hazard and Operability Analysis (HAZOP) is a technique for a system evaluation and determination of risk management of hazards. In particular, HAZOP is used in order to determine potential hazards in a system and operability problems. Moreover, Areal Location of Hazardous Atmosphere (ALOHA) is the potential hazard modelling programme, which is used to plan chemical emergencies. Acetone, a colorless liquid also known as propanone, is a solvent used in manufacture of plastics and other industrial products. The most hazardous property of acetone is its flammability. Acetone is a solvent widely used in the chemical industries and stored in large volumes, therefore, acetone is an important source of danger for chemical processes. In this study, acetone was investigated to be a hazardous chemical using HAZOP and ALOHA software in order to prevent and control a big hazardous event in an industrial plant.&nbsp

LOPA11 All acronym meanings can be found in the nomenclature table at the end of the article. (Layer of Protection Analysis), is a semi-quantitative hazard analysis technique that can be used after a Qualitative Hazard Analysis Techniques such as HAZOP (Hazard and Operability Analysis) technique, and before a QRA (Quantitative Risk Analysis). LOPA can be used to identify the rate of the SIL (Safety Integrity Level), which specifies the level of safety protection and consequently identifies if the safety system is reliable or requires extra protection layers.LOPA has been used in many industrial processes such as LNG (Liquefied Natural Gas), petroleum and petrochemical industries. This study aims at performing the HAZOP technique on a specific node of a DRI (Direct Reduction Iron) industry, followed by LOPA to have quantified results and to determine whether the available independent protection layers (IPLs) in the system are sufficient. Moreover, it identifies the outcome required by the SIL target. Finally, fuzzy logic method for risk assessment is used as an efficient way to estimate the severity and determine the SIL rate to be compared with the one obtained by LOPA study.

This study presents a risk assessment study on an amine-based CO2 capture process. Based on the critical risks identified by a hazard and operability study (HAZOP) conducted in our previous work, we performed detailed quantitative risk assessment, including frequency estimation using fault tree analysis (FTA) and consequence estimation using the process hazard analysis software tool (PHAST). As a result of our FTA study on explosion accidents in the absorber column as a top event, we identified 25 basic events and eight intermediate events that lead to the top event. The probability of a T-102 explosion was estimated to approximately 3.55E-03 per year, which satisfies international safety regulations. Additionally, we performed consequence estimation for three types of accidents in an absorber, namely toxic substance leakage, explosions, and fireballs, under two different weather conditions, namely modest and worst conditions. It was determined that in the event of a toxic substance leakage accident, the effect zone of acid gas with high toxic substance content is approximately four-times larger than that of raw gas.

In this article, a risk assessment of the Nanofluid stabilization process was made in order to optimize the process parameters using the HAZOP methodology. The results showed that the main parameters for the HAZOP risk assessment are as follows: the weight fraction of the surfactant, the temperature when the surfactant is used, the pressure and the speed of the fluid in the homogenizer, the PH solution, the time and the power of ultrasound, the temperature of the stabilization process, the volume fraction of nanoparticles, the size of the nanoparticles, the side surface to the volume of Nano particles, zeta potentials, Nanofluid concentrations. The results of the risk number calculations before control actions showed that after control actions, all risk numbers decreased 50% and more, so this decrease was significant. This decrease showed that all control actions were appropriate and effective.

The purpose of this work is the risk assessment of a stabilizer reflux drum using HAZOP - Fault tree - Event tree approach. This risk assessment approach aims first of all to identify potential accident scenarios using Hazard an Operability study (HAZOP), these scenarios need more detailed frequencies estimation, it is performed thanks to fault tree analysis. Then, to analyze events issuing after success or fail of safety barriers, the event tree is used. Finally, in order to better appreciate accident scenarios, ALOHA is utilized to simulate them.

The safe and reliable operation of the China Fusion Engineering Test Reactor (CFETR) Central Solenoid Model Coil (CSMC) heat treatment system is the basis for the establishment of the CFETR central solenoid, Nb3Sn superconducting coil. The purpose of safety analysis of a heat treatment system is to find out the unreliable factors of the system, analyze the weaknesses of the system, predict the possibility and severity of system failure, and then improve the reliability of the system. The method of combining risk priority number (RPN) with Hazard and operability study (HAZOP) can make up for the deficiency of quantitative information in traditional HAZOP analysis. It is concluded that the fan subsystem is the weakest part of the heat treatment system by means of RPN-HAZOP. The deviation caused by temperature, cleanliness, and impurity gas content will greatly affect the performance of the superconducting coil. The author tries to put forward scientific and reasonable measures according to the principle of giving priority to solving the principal contradiction. Guided by the measures and suggestions, the heat treatment system runs normally, safely, and reliably. The results of the experiment show that all the process indexes meet the requirements of coil heat treatment technology.

Growing popularity of biomass power generation process is connected to its label of green and cheap renewable energy. As the second-largest producer of crude palm oil, Malaysia has abundance of biomass residues from palm oil industries and other renewable organic matters which can be converted to bio-chemicals to generate electricity. However, despite institutional arrangements, policy frameworks, funding mechanisms and incentives to support the growth of the biomass industry, there are several risks which may prone to reduce efficiency of biopower boiler especially empty fruit bunch as the fuels that cannot be ignored. Boiler is one of the primary equipment of power generation plants, in a significant role in converting biofuel to electricity. With increasing numbers of potentials of biomass as raw materials for renewable energy uses, new risks may be found. Yet there has been very little research into these risks and how to prevent them. Lack of understanding of modern risk identification methods, such as HAZOP, with the biopower industry is one of the reasons for the industry’s slow growth. An industry evolves through life cycle stages and at each stage presents risk factors such as overheating, oxygen corrosion and clinker. This paper identifies several key risks associated with EFB fired biopower boiler in Malaysia. The overview of risks not only provide a perspective from which an industry’s viability can be evaluated but also help the operators to better understand key risks and improve boiler capacity as well as plan their risk mitigation strategies more effectively.

Renewable power generation facilities are constantly expanding due to the expected depletion of fossil fuels and the increasingly demanding policy of pollution control. Having said that, hydrogen is one of the promising energy sources. That said, hydrogen chain safety is an unescapable parameter that should continuously coexist with the development of hydrogen domain. In this context, this article presents a contribution to the risk analysis and evaluation of a complex hydrogen production system 'EGA-9000′ at CIEMAT (Centre for Research on Energy, Environment and Technology - Madrid, Spain). The methodology followed in this study revolves around the risk analysis process through a FAST (Functional Analysis System Technique) functional analysis method and a HAZOP (HAZard and Operability) dysfunctional analysis method. The evaluation of the thirty-three scenarios identified by the risk analysis shows that the studied system is insecure. Indeed, five scenarios at an unacceptable level of risk. And it is noted that the risk of fire and explosion is the major risk for all scenarios studied. To this end, safety measures (recommendation) have been proposed based on the weaknesses detected by the risk analysis carried out.

This paper described the method of event tree analysis that is commonly used to identify, characterize and estimate the risk. Quantitative estimates for probability of breach or failure and the resulting consequences can be obtained using event trees. Qualitative depictions of potential failure modes and consequences can also be developed using event trees. An event tree analysis (ETA) is an inductive procedure that shows all possible outcomes resulting from an accidental (initiating) event. An event tree consists of a sequence of interconnected nodes and branches. Each node defines a random variable that represents an uncertain event or state of nature. Branches originating from a node represent each of branches to represent the likelihood for each event or condition. These probabilities are conditional on the occurrence of the preceding events to the left in the tree. Our work includes a HAZOP study to determine the necessary safety barriers as a first step. And as a second step is their evaluation using ETA method of fired heater F201-101, ADRAR refinery, Algeria. This particular method is well suited to estimating the risk stemming from process plant failure. Neither the initiators of industrial accidents nor the layers of protection that prevent them are typically complex, that is, they do not usually require analysis by redundant systems or the time for on-line repair. Thus, they can be accurately characterized with the probability multiplication methods that from the basis of event tree analysis.

Process plant and chemical processes are complex and large systems, consisting of thousands of devices interacting with each other [76][45]. The structure of this type of industrial plants lead to difficulties in process control, hence deviations from the operation objectives or desired states. These deviations creates abnormal situations that drive products out of specification, increased operational costs, shut downs and even worse they can cause accidents, which may lead to damages of equipment, environment and affect the health. identifying hazards is fundamental for ensuring the safe design and operation in process plants. Based on the idea of learning from accidents, several techniques and standards are available to identify hazardous situations and help companies to build up strategies to avoid the hazards. In this s work we present a study based on two methods BOWTIE and HAZOP methods applied for an LPG a plant for gas separation located in SKIKDA refinery which is considered as the most important refinery in Algeria where the treatment capacity reaches more than 15 millions tones per year of crude oil. Several recommendations raised from our study to improve the safety of the plant particularly since it is considered as an old plant start working since 1980. The study is completed by simulating the deduced dangerous scenarios using ALOHA software.

The purpose of this paper is to analyze risk of accidental gasoline release in the storage tank of gasoline 59-TK-158 situated in complex GL1/K Skikda using quantitative risk assessment based on HAZOP and bow tie to identify and quantify the sources of the unwanted event. Afterward, we identified the areas that are exposed to different industrial accidental effects such as (thermal, flammable and overpressure), using the software Phast as a tool for simulation. The simulation results show the distances of the affected area, to understand the risk consequences related to the affected area of each scenario. Based on this simulation, using the societal risk curves FN to assess the accidental risk inevitably affects people in the surrounding area. This explicitly denotes the relation between the frequency of occurrence and the number of fatalities generated by this accident on a two-dimensional diagram. It aims to find which scenario that is acceptable and which needs more improvement to lower the consequences related to it in a matter of safety. This work was conducted for the first time in GNL Skikda, specifically in a storage tank using a combination between HAZID, bow tie and FN curve. The intention of this combination is to explain deferent industrial phenomenal specially to avoid disasters such as what happened in 2004 and 2005 in the industrial area of Skikda. That is what makes the approach practically more helpful in the use of safety barriers and industrial decision making.

This paper presents an investigation of hazard sources identification and reliability sensitivity analysis of CTCS-3 on-board subsystem. Traditional quantitative and qualitative safety and reliability analysis generally used static analysis methods, such as Fault Tree. When device redundancy, dynamic logic and dynamic mechanism are taken into consideration, dynamic analysis methods are preferred, such as Dynamic Fault Tree (DFT). In this paper, the methods of Hazards and Operability (HAZOP), DFT and Monte Carlo Simulation (MCS) are used for quantitative and qualitative analysis. Firstly, to reflect the structure and functions of on-board subsystem, two models (i.e reference model and function hierarchical model) are built. HAZOP is applied to identify hazard sources of on-board subsystem according to above models. Secondly, DFT is put forward within which the top event is CTCS-3 on-board subsystem failure event and the basic events are from results of HAZOP analysis. Then, both MCS and Maximum Likelihood Estimation (MLE) are adopted to estimate the reliability parameters of the CTCS-3 on-board subsystem and components. Reliability sensitivity analysis is observing the variations in components’ reliability parameter contributing to the changes of Mean Time to Failure (MTTF) of CTCS-3 on-board subsystem. Finally, a failure density curve of CTCS-3 on-board subsystem and a table of MTTF sensitivity parameters are presented. According to the sensitivity table, it is knowledgeable for decision makers to take effective measures to improve the reliability of CTCS-3 on-board subsystem.

Conventional HAZOP is a collaborative and multidisciplinary activity to identify the hazards associated to operability of the chemical processes. Then the consequences and required safeguards of each potential deviation or failure are assessed qualitatively one by one. It is performed with the assumption of "one failure at the time" for the process parameters. Furthermore, process complexities such as multiple failures, domino effects, time and amplitude dependent deviations etc. are avoided to keep the HAZOP brainstorming sessions systematic and effective. Therefore, the quality and outcomes of HAZOP study are relatively subjective and depend on the experience and competency of the HAZOP team. This simplified approach cannot fully cover the hazard identification and risk assessment of the complex processes such as polymerization. Furthermore, the incident investigations show that almost all major accidents have occurred due to multiple failures or domino effects. This paper aims at developing a practical methodology in the context of "Industry 4.0" and particularly illustrate how dynamic simulation liberates the HAZOP team from the simplification assumptions such as one failure at the time or neglecting the domino effects during the lifecycle of the complex processes. An industrial styrene bulk free radical polymerization process has been chosen as the case study to depict the applicability of the proposed method. In continuation of this research, the dynamic simulation integrated with Artificial Intelligence (AI) algorithms and Multivariable Process Monitoring (MPM) together with virtual collaboration tools will be invoked towards a more practical and effective HAZOP 4.0 platform. Such a platform can be the foundation of the further Process Safety Management (PSM) elements such as "Operating manuals", "Training and Competency management", "Condition monitoring and predictive maintenance", "Management of Change", "Pre-Start-up Safety Review", etc.

Commercial biodiesel production through transesterification of refined bleached & deodorized palm oil (RBDPO) with methanol is commonly performed in macroscale reactors. This work focused on the comparison of biodiesel production system in terms of production efficiency and safety evaluation for both conventional and microreactor systems based on the industrial production capacity of 20,589.29 L/h. Our demonstration of the laboratory biodiesel production provided high quality of biodiesel comparable to the commercial biodiesel. Design of microreactor system for scaling-out to industrial capacity was performed. The simple layout of microreactor system provided great flexibility for operation and maintenance. Less energy consumption and a small number of operators relative to the conventional biodiesel production plant are required. Safety evaluation based on HAZOP and FMEA suggested that the microreactor system was relatively safer than that of the conventional one. The risk can be further reduced by regularly maintaining and calibrating equipment according to preventive maintenance schedule.

PT. XYZ is a company engaged in oil palm plantations and processing with its main commodity is the oil palm plantations (Elais Queineensis Jack). In 2018, thare are several occupational safety and health problems naamely occupational accidents experienced by special employees in the production processarea. The purpose of this study is to detemine the types of work accidents, the types of hazards created based on the risk materics. This study begins by identifying Hazard and risk and then looking for potential sources of occuptional hazard so that harm can be done using the Hazard and Operability Study (HAZOP) method. The research results have been carried out based on the process (Crude Palm Oil) found 8 sources of potential danger between : Loding Ramp Station, Sterilizer Station, Tippler Station, DigesterStation, Press Station, Clarification Station, Kernel Stationdan Boiler Station, then risk assessment : low risk, medium risk, high risk and extreme risk.

The heavy base oils are traditionally treated using concentrated hot acid to remove various polycyclic aromatic hydrocarbons. The hot acid treatment poses operational safety issues at the supplier end whereas a cancer hazard at the consumer end. An alternative to the hot acid treatment is the hydrogenation of heavy base oils. The feasibility for hydrogenation of various base oils was studied in a semi-pilot-scale Fixed Bed Reactor (FBR) by us. For some of the highly viscous heavy base oils, the serious issue of choking inside the semi-pilot-scale setup was observed. This problem motivates us to further investigate the issues associated with FBR at the pilot-scale where less men power and minimum automation are involved. The FBR is vulnerable to overpressure and overtemperature scenarios when a multiphase exothermic reaction is carried out under severe conditions. The present study is the preventive measure taken by us at the early stage of process development in which we evaluate probabilistic chances of overpressure-induced mechanical explosion in FBR. The factors leading to an overpressure scenario were identified using the qualitative approach of HAZOP and Directed Acyclic Graph (DAG). The prior failure probabilities were estimated using Fault Tree Analysis (FTA) and Bayesian Network Analysis (BNA). Later the posterior probabilities were estimated using BNA and different scenarios were compared. For an overpressure scenario, high gas inflow, low liquid outflow and operator actions are critical factors. The reliability of the safety relief valve, safety relief valve tension and pressure measurement is the most critical and shows maximum improvement indices.

Over the past five years, work accident cases in Indonesia have continued to increase and reached the highest point in 2020 of 177,000 cases. This proves that steps are needed to reduce the number of work accidents by conducting a risk assessment in accordance with the main objective of K3, namely creating a safe work environment by conducting qualitative and quantitative assessments. This study aims to design a proposed improvement in the PAM JAYA building construction project by identifying the existing hazards and determining the level of risk using the Hazard of Operability Study method. The HAZOP method was chosen because its work is systematic, structured, thorough, and very suitable to be applied to the system newly implemented, in this study the PAM JAYA building construction project which has only been running for several months. This study finds 5 findings of extreme risk level hazards, 12 findings of high risk level hazards, 2 findings of medium risk level hazards, and 1 finding of low risk level hazards in the PAM JAYA building construction project. The suggestions for improvement given in this study are based on five hierarchies of risk control, such as Elimination, Substitution, Engineering, Administrative Control, and Use of PPE

The Hazard and Operability Study (HAZOP) methodology is considered one of the most effective techniques for risk analysis, developed fundamentally to provide regular processes with reduced risks that aim to guarantee the safety of activities and the operability of the production units. The study aims to apply the HAZOP methodology in process and safety operations in the oil production industry. A crude oil production unit was divided into smaller sections that were analysed. By applying the HAZOP methodology, 71 possibilities of relevant risks were identified. The environmental, health and economic impacts were estimated to establish safeguard priorities for them. The application of this methodology and the defined safeguards generated 47 recommendations to mitigate the detected problems. The study contributions were to demonstrate the efficacies of HAZOP methodology to identify potential hazards and evaluate the potential hazards obtained for malfunctioning of equipment and property in terms of the resultant impacts either new or existing process facilities, and as a useful tool to provide essential knowledge for the companies’ leaders, decision-maker, and operations managers.

Traditional hazard and operability analysis (HAZOP) is one of the most widely applied methods for process safety management in process enterprises. Due to its principles based on the conservative and qualitative judgment, it often leads to too conservative risk identification results for the fluorine chemical industry usually with high-risk processes to keep the continuity of production. Most of improved quantitative and semi-quantitative methods are based on the layer of protection analysis (LOPA) to resolve the over-conservative problem of traditional HAZOP with the database of LOPA. However, the improved model, taking LOPA as the main line and HAZOP only as the provider of scenarios and influencing factors, is limited to the fact that LOPA can only analyze complete and independent protection layers (IPLs). Therefore, in order to realize the quantitative or semi-quantitative analysis of disaster causes and consequences, a new semi-quantitative HAZOP method takes HAZOP as the main line to integrate LOPA, F&amp, EI (fire and explosion index) for quantitatively calculating the reduction factors, probability on failure demand (PFD) of general protection layers (GPLs) and PFD of IPLs. With the case comparison of fluorine chemical industry, it is proved that this new method can effectively improve the problem that traditional HAZOP are too conservative in complex scenarios.

We propose a methodology for analyzing the hazards and potential mitigation of faults and failures in an Advanced Driver Assistance System (ADAS) which is applicable to individual systems and subsystems of a larger automated vehicle implementation. To illustrate the methodology, we outline the structure of an notional overtaking assistant, considering that the system would not only need internal sensors such as global navigation satellite system (GNSS) receivers, map data, and other motion and localization sensors and external sensors such as radars, lidars, and vision systems but also access to cooperative positioning information through a wireless connected vehicular network in order to identify the location of oncoming traffic. Then, we perform the hazard analysis of this subsystem utilizing a combination of methods. For the vehicle level hazard analysis we use Hazard Operability Study (HAZOP) and the first step of System Theoretic Process Analysis (STPA), and for the overall safety analysis we use Failure Mode and Effects Analysis (FMEA) and the second step of STPA. An overtaking assistant for automated vehicles is considered a type of Advanced Driver Assistant System (ADAS) that assists a partially or fully automated vehicle with an overtaking maneuver consisting of acceleration and steering control during a double lane change. Crash data indicates that although only 19% of the US population inhabits rural zones, 54% of the vehicular crashes happen on rural roads [1], with a high number of those events occurring during an overtaking maneuver on two-lane rural roads. While such an overtaking assistant would help to minimize these collision events, no commercial product is yet available due in part to the challenge of defining what constitutes safe navigation in these systems. The analysis performed on the system is presented and is proposed for use as a general methodology to analyze hazards in any ADAS system or subsystem. The summary of the analysis results provided here include a list of hazards and mitigation strategies for the proposed two-lane rural road scenario.

Developing safety-critical products like cars, trains, or airplanes requires rigor in following development processes, and evidence for product safety must be collected. Safety needs to be considered during each development step and traced through the development life cycle. The current standards and approaches focus on single human-operated products. The technical evolution enables integrating existing products and new autonomous products into system-of-systems to automate workflows and production streams. Developing safety-critical systems-of-systems requires similar processes and mapping to safety-related activities. However, it is unclear how to consider safety during different development steps for a safety-critical system-of-systems. The existing hazard analysis methods are not explicitly mapped to developing a system-of-systems and are vague about the required information on the intended behavior. This paper focuses on the concept phase for developing a system-of-systems, where different technical concepts for a specific product feature are evaluated. Specifically, we concentrate on the evaluation of the safety properties of each concept. We present a process to support the concept phase and apply a model-driven approach to capture the system-of-systems’ relevant information. We then show how this knowledge is used for conducting an FMEA and HAZOP analysis. Lastly, the results from the analysis are mapped back into the sequence diagrams. This information is made available during the next development stages. We apply the method during the concept phase for designing an industrial system-of-systems. Our approach helps to design complex system-of-systems and supports concept evaluation considering the criticality of the concept under consideration.

The food industry’s failure in planning and designing of and in implementing a Food Safety Management System and its foundation elements leads, in most instances, to compromised food safety and subsequent foodborne illness outbreaks. This phenomenon was noticed, worldwide, for all food processors, but with a much higher incidence in the medium- and small-sized food processing plants. Our study focuses on the importance of Food Safety Management System (FSMS), Critical Control Points Hazard Analysis (HACCP) and the Prerequisite Programs (PRPs) as the foundation of HACCP, in preventing foodborne outbreaks. For emphasis, we make use of the example of organizational food safety culture failures and the lack of managerial engagement which resulted in a multi-state listeriosis outbreak in USA. Moreover, we correlate this with microbiological criteria. Implementation of food safety management systems (ISO 22000:2018) along with incorporation of management tools such as HAZOP, FMEA, Ishikawa and Pareto have proved to be proactive in the maintenance of a positive food safety culture and prevention of cross-contamination and fraud.

Hazardous area classification provides a demonstrable methodology to identify areas in oil field where need to prevent fire and explosion with the potential risk of explosive atmosphere, and sources of ignition, and it is the significant guideline for oil field development. Hazardous Area Classification is important for international oilfield surface facilities, and it is not only the basis of Hazard and Operability Research (HAZOP) for the overall layout of the process in oilfield, but also provides necessary technical support for equipment selection and procurement. Due to the different developmental and technology level of petroleum industry, the standards and norms for Hazardous Area Classification are also different in the world.